3D Textile Lamination Method for Decorative Glass Panels
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Solution Overview
Problem
Existing laminated glazing methods fail to preserve the three-dimensional appearance of textile coatings during encapsulation, as conventional methods crush the fragile texture of these coatings, losing their aesthetic value.
Innovation Solution
A method involving a specific temperature/pressure profile using a PVB lamination insert, where the depression phase occurs simultaneously with the heating phase, with a temperature rise of 2.6°C/min and pressure drop of 0.8×10^4 Pa/min, maintaining these conditions between 70°C and 100°C, and ambient pressure, to prevent crushing and retain the 3D structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional encapsulation methods are used, then the textile coating is encapsulated between glass panes, but the 3D texture is crushed and lost under vacuum depression
Solution Approach 1:
The patent applies preliminary action by initiating the heating phase simultaneously with the vacuum phase, rather than applying vacuum first. The temperature rises from ambient to 70-100°C while the vacuum is being applied, so that when maximum vacuum is reached, the textile has already been warmed and becomes more resilient, preventing crushing of the 3D texture during encapsulation
Solution Approach 2:
The patent changes physical parameters by controlling the temperature rise rate (2.6°C/min) and maintaining temperature between 70-100°C during vacuum application. This parameter control ensures the textile reaches an optimal state where it can withstand vacuum pressure without losing its three-dimensional structure
2Productivity
If rapid heating is applied during vacuum phase, then production time is reduced, but the 3D textile texture is crushed due to thermal stress
Solution Approach 1:
The patent optimizes the heating rate parameter to 2.6°C/min, which is a controlled moderate rate rather than rapid heating. This parameter setting allows the textile to gradually adapt to temperature changes while under vacuum, preventing thermal stress that would crush the 3D texture, while still maintaining reasonable production efficiency
Solution Approach 2:
The patent maintains continuous simultaneous action of heating and vacuum application throughout the process, ensuring that the textile is continuously warmed and supported during the entire vacuum phase, preventing any moment where cold, fragile textile would be subjected to crushing pressure
3Manufacturing precision
If vacuum is applied before heating, then air bubbles are removed effectively, but the textile texture is crushed under depression
Solution Approach 1:
The patent reverses the conventional sequence by applying preliminary heating action simultaneously with vacuum application, rather than applying vacuum first. This ensures the textile is warmed and becomes more resilient before and during the vacuum phase, allowing effective bubble removal without crushing the 3D texture
Solution Approach 2:
The patent creates a composite system where the PVB interlayer, glass panes, and heated textile work together as an integrated unit. The PVB interlayer provides continuous support to the textile during the vacuum process, allowing bubble removal while maintaining the textile's three-dimensional structure through the combined effect of controlled heating and vacuum
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively preserves the three-dimensional appearance of textile materials within the glazing, maintaining their aesthetic appeal while providing protection from dust and solar aggressions, and optionally filtering UV rays to prevent color modification.
Implementation Method 1
a lamination interlayer made of PVB
Implementation Method 2
a heating phase, a temperature holding phase, and a cooling phase of said unit... the heating phase is ensured with a temperature rise slope of the order of 2.6°C/min
Implementation Method 3
a vacuum phase, a vacuum holding phase and a phase of returning to ambient pressure... the vacuum phase begins simultaneously with the heating phase
Implementation Method 4
a cooling phase of said unit... The cooling phase can be achieved with a temperature decrease rate of approximately 2.6°C/min
Data Source
Figure 1~3
Figure 4~6
AI summary
The present invention relates to a laminated glass unit comprising a core (1) at least one face of which is bonded to an external glass substrate (3) by a lamination interlayer, characterized in that the core (1) is made of a 3D textile coating. The present invention also relates to a method for manufacturing such a glass unit.